PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE 293-6125 TRANSMISSION INPUT GROUP ON CERTAIN AD55B UNDERGROUND TRUCKS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE 293-6125 TRANSMISSION INPUT GROUP ON CERTAIN AD55B UNDERGROUND TRUCKS

Usage:

REBE6082-00

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21May2010

U-181

A-142

D-159

O-164

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE 293-6125 TRANSMISSION INPUT GROUP ON CERTAIN AD55B UNDERGROUND TRUCKS
3063 3108 3030		PI31748

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31748" as the Part Number and "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. Exception: If the repair is done after failure, use "PI31748" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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NOTE:

The information supplied in this service letter may not be valid after the termination date of this program. Do not perform the work outlined in this Service Letter after the termination date without first contacting your Caterpillar product analyst.

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COMPLETION DATE	TERMINATION DATE
30Nov2010	31May2011

PROBLEM

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The 3D1101 Bearing, 293-6126 Yoke, and 293-6128 Retainer need to be replaced on certain AD55B Underground Trucks. The existing 3D1101 Bearing, 293-6126 Yoke, and 293-6128 Retainer can overheat and fail.

AFFECTED PRODUCT

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Model	Identification Number
AD55B	JNW00101-00115, 117-136, 138-140, 142-152, 154-155, 157-158, 160, 162-164, 166

PARTS NEEDED

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Qty	Part Number	Description
1	2H3932	SEAL-O RING
2	3D1100	CUP-ROLLER BRG
2	3D1101	CONE-SPL TAPERED
1	5J2383	SEAL-O RING
1	6M5218	SEAL-O RING
1	9M4218	SEAL-O-RING
1	9M7002	SEAL-O-RING
1	1334296	SEAL-LIP TYPE
1	2936130	SHIM-PACK
1	3512817	RETAINER-BEARING
1	3512819	YOKE-U JOINT
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.

ACTION REQUIRED

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Refer to the attached Rework Procedure.

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OWNER NOTIFICATION

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U.S. and Canadian owners will receive the attached Owner Notification.

SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 12.0-hour job

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PARTS DISPOSITION

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Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

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COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE 293-6125 TRANSMISSION INPUT GROUP ON CERTAIN AD55B UNDERGROUND TRUCKS

MODELS INVOLVED - AD55B Underground Trucks

Dear Caterpillar Product Owner:

The 3D1101 Bearing, 293-6126 Yoke, and 293-6128 Retainer need to be replaced on the products listed below. The existing 3D1101 Bearing, 293-6126 Yoke, and 293-6128 Retainer can overheat and fail. You will not be charged for the service performed.

Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.

Please refer the dealer to their Service Letter dated 21May2010 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed as soon as possible to prevent unscheduled downtime.

Caterpillar Inc.

Identification #(s)

Attached to 21May2010 Service Letter

Rework Procedure

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AD55B Transmission Input Group Rework Procedure

Reference KENR6708 ?Drive Shaft (Upper) ? Remove and Install?
Reference KENR6708 ?Input Drive from Transmission-Separate/Connect?
Reference KENR6708 ?Input Drive-Disassemble/Assemble?
Reference 351-2833 Bearing Adjustment Instructions

Image1.2.1

Start By:

A. Connect the steering frame lock. Refer to Disassembly and Assembly, "Steering Frame Lock - Separate and Connect".

B. Install the body retaining pins. Refer to Disassembly and Assembly, "Body Retaining Pins - Remove and Install".

C. Remove the upper drive shaft. Refer to Disassembly and Assembly, "Upper Drive Shaft - Remove and Install".

Note: Transmission will not be removed from vehicle.

Image1.4.1

1. Remove four bolts (94), bracket (93) and two spacers (92) .

Image1.6.1

2. Remove 2 bolts (2) and use them to attach tooling (A) in locations shown. Do not tighten these bolts completely until removing 13 additional bolts (2).

3. Remove 13 bolts (2).

Note: Use 2 bolts (2) as jacking bolts in order to separate input drive (1)

Image1.7.1

4. Remove four O-ring seals (3). These seals will be replaced later.

Image1.8.1

5. Remove five bolts (4).

Image1.9.1

6. Turn the input drive assembly over. The weight of the input drive assembly is approximately 102 kg (225 lb). Remove eight bolts (5) and bearing retainer (7) from yoke (6). Bearing retainer (7) will be replaced later.

Image1.10.1

7. Remove shims (8), bearing (9) and yoke (6). Bearing (9) will be replaced later.

Image1.11.1

8. Remove bearing (10), O-ring seal (11) and bearing cover (12) from yoke (6) . Bearing (10) will be replaced later. Yoke (6) will be replaced later.

Image1.12.1

9. Remove seal (13) from bearing cover (12). Seal (13) will be replaced later.

Image1.13.1

10. Remove bearing cups (14) from the cover. Bearing cups (14) will be replaced later.

Image1.14.1

11. Lower the temperature of two new bearing cups (14) and install into the cover. Ensure bearing cups (14) are properly seated against each shoulder.

Image1.15.1

12. Install new seal (13) into bearing cover (12).

Note: The sealing lip must be facing the inside of bearing cover (12).

Image1.16.1

13. Install bearing cover (12), new O-ring seal (11) and new bearing (10) to yoke (6). Lubricate O-ring seal (8) with the lubricant being sealed.

Image1.17.1

14. Install front cover onto yoke (6). The weight of the input cover is approximately 102 kg (225 lb). Install new bearing (9). Rotate input cover to seat bearings.

Note: Five bolts to attach bearing cover to input cover are not installed at this time.

Image1.18.1

15. Install shim measuring fixture (D) to yoke with three bolts (5). Torque three bolts (5) to 5 N-m while rotating input cover to seat bearings. Continue rotating housing while applying 5 N-m torque to bolts (5) until bolts stop advancing.

Image1.19.1

Image1.19.2

16. Use tooling (C) to measure the distance between the end of the output yoke (6) and the bearing (9). Record this dimension as dimension (M). Note: The thickness of the shims to install should be 0.0762-0.1778 mm (.003-.007 in) greater than dimension (M).

Image1.20.1

17. Remove tooling (C) then install correct shims (8), retainer (7), and eight bolts (5). Torque eight bolts (5) to 25 +/- 6 N-m in a criss-cross pattern.

Image1.21.1

18. Install five bolts (4) to secure bearing cover (12) to input cover. Be sure seal (11) is properly positioned in seal groove in bearing cover (12).

Image1.22.1

19. Turn input drive assembly over. The weight of the input drive assembly is approximately 102 kg (225 lb). Torque five bolts (4) to 25 +/- 6 N-m. Tap yoke (6) down gently with dead blow mallet. Install tool (F). Pry yoke (6) up to measure bearing endplay. Endplay should be .000?-.003? (0.00-0.08 mm). If not, go back to step 17 and add or remove shims appropriately.

Image1.23.1

20. Install tooling (E) to yoke (6).

Image1.24.1

21. Measure the rolling torque of the yoke. If the rolling torque is greater than 4 N-m then go back to step 17 and add or remove shims as appropriate.

22. Assemble input group to transmission by performing steps 1-4 in reverse order. Remember to install new seals and torque bolts (2) to 105+/-20 N-m.